Venting of deflagrations: hydrocarbon–air and hydrogen–air systems

A set of 34 experiments on vented hydrocarbon–air and hydrogen–air deflagrations in unobstructed enclosures of volume up to 4000 m³ was processed with use of the advanced lumped parameter approach. Reasonable compliance between calculated pressure–time curves and experimental pressure traces is demonstrated for different explosion conditions, including high, moderate, low and extremely low reduced overpressures in enclosures of different shape (L_max:L_min up to 6:1) with different type and position of the ignition source relative to the vent, for near-stoichiometric air mixtures of acetone, methane, natural gas and propane, as well as for lean and stoichiometric hydrogen–air mixtures. New data were obtained on flame stretch for vented deflagrations.The fundamental Le Chatelier–Brown principle analog for vented deflagrations has been considered in detail and its universality has been confirmed. The importance of this principle for explosion safety engineering has been emphasized and proved by examples.A correlation for prediction of the deflagration–outflow interaction number, χ/μ, on enclosure scale, Bradley number and vent release pressure is suggested for unobstructed enclosures and a wide range of explosion conditions. Fractal theory has been employed to verify the universality of the dependence revealed of the deflagration–outflow interaction number on enclosure scale.In spite of differences between the thermodynamic and kinetic parameters of hydrocarbon–air and hydrogen–air systems, they both obey the same general regularities for vented deflagrations, including the Le Chatelier–Brown principle analog and the correlation for deflagration–outflow interaction number.     

Propane-air mixture deflagration hazard with different ignition positions and restraints in large-scale venting chamber

In order to better assess the hazards of explosion accidents, propane-air mixture deflagrations were conducted in a large-scale straight rectangular chamber (with a cross-section of 1.5 m × 1.5 m, length of 10 m, and total volume of 22.5 m³). The effect of initial volume, ignition position, and initial restraints on the explosion characteristics of the propane-air mixtures was investigated. The explosion overpressure, flame propagation, and flame speed were obtained and the computational fluid dynamics (CFD) software was used to simulate the flame-propagation process and field flow for auxiliary analysis. The hazards of large-scale propagation explosion under weak and strong constraints were evaluated and the different phases of flame propagation under weak and strong constraints were discriminated. Results indicate that the hazards caused by propane deflagration under weak constraint are mainly caused by flame spread. And the maximum overpressure under strong constraint appeared at the front part of the chamber under the large-scale condition, which is consistent with the previous small-scale test. Moreover, the simulations of flame structures under weak and strong constraint are in good agreement with experimental results, which furthers the understanding of large-scale propane deflagration under different initial conditions in large-scale spaces and provides basic data for three-dimensional CFD model improvement.     

Flame propagation behaviors of nano- and micro-scale PMMA dust explosions

Flame propagation behaviors of nano- and micro-polymethyl methacrylate (PMMA) dust explosions were experimentally studied in the open-space dust explosion apparatus. High-speed photography with normal and microscopic lenses were used to record the particle combustion behaviors and flame microstructures. Simple physical models were developed to explore the flame propagation mechanisms. High-speed photographs showed two distinct flame propagation behaviors of nano- and micro-PMMA dust explosions. For nano-particles, flame was characterized by a regular spherical shape and spatially continuous combustion structure combined with a number of luminous spot flames. The flame propagation mechanism was similar to that of a premixed gas flame coupled with solid surface combustion of the agglomerates. In comparison, for micro-particles, flame was characterized by clusters of flames and the irregular flame front, which was inferred to be composed of the diffusion flame accompanying the local premixed flame. It was indicated that smaller particles maintained the leading part of the propagating flame and governed the combustion process of PMMA dust clouds. Increasing the mass densities from 105 g/m³ to 217 g/m³ for 100 nm PMMA particles, and from 72 g/m³ to 170 g/m³ for 30 μm PMMA particles, the flame luminous intensity, scale and the average propagation velocity were enhanced. Besides, the flame front became more irregular for 30 μm PMMA dust clouds.     

CFD modelling of hydrogen and hydrogen-methane explosions – Analysis of varying concentration and reduced oxygen atmospheres

This paper evaluates the predictive capabilities of the advanced consequence model FLACS-CFD for deflagrations involving hydrogen. Two modelling approaches are presented: the extensively validated model system originally developed for hydrocarbons included in FLACS-CFD 22.1 and a Markstein number dependent model implemented in the in-house version FLACS-CFD 22.1 IH. The ability of the models to predict the overpressure and the flame arrival time for scenarios with different concentrations of hydrogen, and thus different Lewis and Markstein numbers, is assessed. Furthermore, the effect of adding methane or nitrogen on overpressure for different regimes of premixed combustion are investigated. The validation dataset includes deflagrations in the open or in congested open areas and vented deflagrations in empty or congested enclosures. The overpressure predictions by FLACS-CFD 22.1 IH are found to be more accurate than those obtained with FLACS-CFD 22.1 for scenarios with varying hydrogen concentrations and/or added nitrogen or methane in the mixture. The predictions by FLACS-CFD 22.1 IH for lean hydrogen mixtures are within a factor of 2 of the values observed in the experiments. Further development of the model is needed for more accurate prediction of deflagrations involving rich hydrogen mixtures as well as scenarios with other fuels and/or conditions where the initial pressure or temperature deviate significantly from ambient conditions.     

Flame propagation mechanisms in dust explosions

To reveal the effects of particle characteristics, including particle thermal characteristics and size distributions, on flame propagation mechanisms during dust explosions clearly, the flame structures of dust clouds formed by different materials and particle size distributions were recorded using an approach combining high-speed photography and a band-pass filter. Two obviously different flame propagation mechanisms were observed in the experiments: kinetics-controlled regime and devolatilization-controlled regime. Kinetics-controlled regime was characterized by a regular shape and spatially continuous combustion zone structure, which was similar to the premixed gas explosions. On the contrary, devolatilization-controlled regime was characterized by a complicated structure that exhibited heterogeneous combustion characteristics, discrete blue luminous spots appeared surrounding the yellow luminous zone. It was also demonstrated experimentally that the flame propagation mechanisms transited from kinetics-controlled to devolatilization-controlled while decreasing the volatility of the materials or increasing the size of the particles. Damköhler number was defined as the ratio of the heating and devolatilization characteristic time to the combustion reaction characteristic time, to reflect the transition of flame propagation mechanisms in dust explosions. It was found that the kinetics-controlled regime and devolatilization-controlled regime can be categorized by whether Damköhler number was less than 1 or larger than 1.     

Experimental investigation on explosion flame propagation of wood dust in a semi-closed tube

In order to explore flame propagation characteristics during wood dust explosions in a semi-closed tube, a high-speed camera, a thermal infrared imaging device and a pressure sensor were used in the study. Poplar dusts with different particle size distributions (0–50, 50–96 and 96–180 μm) were respectively placed in a Hartmann tube to mimic dust cloud explosions, and flame propagation behaviors such as flame propagation velocity, flame temperature and explosion pressure were detected and analyzed. According to the changes of flame shapes, flame propagations in wood dust explosions were divided into three stages including ignition, vertical propagation and free diffusion. Flame propagations for the two smaller particles were dominated by homogeneous combustion, while flame propagation for the largest particles was controlled by heterogeneous combustion, which had been confirmed by individual Damköhler number. All flame propagation velocities for different groups of wood particles in dust explosions were increased at first and then decreased with the augmentation of mass concentration. Flame temperatures and explosion pressures were almost similarly changed. Dust explosions in 50–96 μm wood particles were more intense than in the other two particles, of which the most severe explosion appeared at a mass concentration of 750 g/m³. Meanwhile, flame propagation velocity, flame propagation temperature and explosion pressure reached to the maximum values of 10.45 m/s, 1373 °C and 0.41 MPa. In addition, sensitive concentrations corresponding to the three groups of particles from small to large were 500, 750 and 1000 g/m³, separately, indicating that sensitive concentration in dust explosions of wood particles was elevated with the increase of particle size. Taken together, the finding demonstrated that particle size and mass concentration of wood dusts affected the occurrence and severity of dust explosions, which could provide guidance and reference for the identification, assessment and industrial safety management of wood dust explosions.     

Theoretical pressure prediction of confined hydrogen explosion considering flame instabilities

In order to ensure the safe utilization of hydrogen energy, the explosion pressure behavior is extremely important to design chemical equipment and evaluate explosion accident consequence. This paper is aimed at establishing a theoretical method of predicting explosion pressure behavior in the confined chamber by considering flame instabilities. The tendency of flame wrinkling factor in the pressure-buildup stage is firstly evaluated using large eddy simulation and the compensation theory. The limiting value of flame wrinkling factor during entire explosion process is calculated using the fractal theory. Finally, the dynamic model of flame wrinkling factor is implemented into the smooth flame model. The results demonstrated that the flame wrinkling factor in the pressure-buildup stage almost increases linearly with time. The limiting value of flame wrinkling factor is 2.4649. The explosion pressure will be underestimated using the smooth flame model, and the calculated explosion pressure in the isothermal condition is smaller than that in the adiabatic condition. When the fully turbulent flame is considered, the explosion pressure will be overpredicted significantly. By changing the confined chamber size, the explosion pressure could be reproduced relatively satisfactorily when the flame wrinkling factor is assumed to increase exponentially. The explosion pressure prediction must consider the effect of adiabatic compression and flame instabilities on burning rate.     

Suppression of metal dust deflagrations

Dust explosions continue to pose a serious threat to the process industries handling combustible powders. According to a review carried out by the Chemical Safety Board (CSB) in 2006, 281 dust explosions were reported between 1980 and 2005 in the USA, killing 119 workers and injuring 718. Metal dusts were involved in 20% of these incidents. Metal dust deflagrations have also been regularly reported in Europe, China and Japan.The term “metal dusts” encompasses a large family of materials with diverse ignitability and explosibility properties. Compared to organic fuels, metal dusts such as aluminum or magnesium exhibit higher flame temperature (T_f), maximum explosion pressure (P_max), deflagration index (K_St), and flame speed (S_f), making mitigation more challenging. However, technological advances have increased the efficiency of active explosion protection systems drastically, so the mitigation of metal dust deflagrations has now become possible.This paper provides an overview of metal dust deflagration suppression tests. Recent experiments performed in a 4.4 m³ vessel have shown that aluminum dust deflagrations can be effectively suppressed at a large scale. It further demonstrates that metal dust deflagrations can be managed safely if the hazard is well understood.     

Effects of hydrogen addition on propagation characteristics of premixed methane/air flames

An experimental study has been conducted to investigate the effects of hydrogen addition on the fundamental propagation characteristics of methane/air premixed flames at different equivalence ratios in a venting duct. The hydrogen fraction in the methane–hydrogen mixture was varied from 0 to 1 at equivalence ratios of 0.8, 1.0 and 1.2. The results indicate that the tendency towards flame instability increased with the fraction of hydrogen, and the premixed hydrogen/methane flame underwent a complex shape change with the increasing hydrogen fraction. The tulip flame only formed when the fraction of hydrogen ranged from 0 to 50% at an equivalence ratio of 0.8. It was also found that the flame front speed and the overpressure increased significantly with the hydrogen fraction. For all equivalence ratios, the stoichiometric flame (Φ = 1.0) has the shortest time of flame propagation and the maximum overpressure.     

Effects of cross-wise obstacle position on methane–air deflagration characteristics

A vented chamber, with internal dimensions of 150 mm × 150 mm × 500 mm, is constructed in which the premixed methane–air deflagration flame, propagating away from the ignition source, interacts with obstacles along its path. Three obstacle configurations with different cross-wise positions are investigated. The cross-wise obstacle positions are found to have significant effects on deflagration characteristics, such as flame structure, flame front location, flame speed, and overpressure transients. The rate of flame acceleration, as the flame passes over the last obstacle, is the highest at the configuration with three centrally located obstacles, whereas the lowest is observed at the configuration with three obstacles mounted on one side of the chamber. Compared with the side configuration, the magnitude of overpressure generated increases by approximately 80% and 165% for the central and staggered configurations, respectively. Furthermore, flame propagation speeds and generated overpressures for both the central and staggered configurations are greater, which should to be avoided to reduce the risk associated with turbulent premixed deflagrations in practical processes.     

A study of the blast wave shape from elongated VCEs

Elongated congestion patterns are common at chemical processing and petroleum refining facilities due to the arrangement of processing units. The accidental vapor cloud explosion (VCE) which occurred at the Buncefield, UK facility involved an elongated congested volume formed by the trees and undergrowth along the site boundary. Although elongated congested volumes are common, there have been few evaluations reported for the blast loads produced by elongated VCEs. Standard VCE blast load prediction techniques do not directly consider the impact of this congested volume geometry versus a more compact geometry.This paper discusses an evaluation performed to characterize the blast loads from elongated VCEs and to identify some significant differences in the resulting blast wave shape versus those predicted by well-known VCE blast load methodologies (e.g., BST and TNO MEM). The standard blast curves are based on an assumption that the portion of the flammable gas cloud participating in the VCE is hemispherical and located at grade level. The results of this evaluation showed that the blast wave shape for an elongated VCE in the near-field along the long-axis direction is similar to that for an acoustic wave generated in hemispherical VCEs with a low flame speed. Like an acoustic wave, an elongated VCE blast wave has a very quick transition from the positive phase peak pressure to the negative phase peak pressure, relative to the positive phase duration. The magnitude of the applied negative pressure on a building face depends strongly on the transition time between the positive and negative phase peak pressures, and this applied negative phase can be important to structural response under certain conditions. The main purpose of this evaluation was to extend previous work in order to investigate how an elongated VCE geometry impacts the resultant blast wave shape in the near-field. The influence of the normalized flame travel distance and the flame speed on the blast wave shape was examined. Deflagration and deflagration-to-detonation transition regimes were also identified for unconfined elongated VCEs as a function of the normalized flame travel distance and flame speed attained at a specified flame travel distance.     

Experimental study on the fractal characteristic of methane explosion flame

In this paper flame microstructures and propagation characteristic of methane explosion are studied by high speed schlieren photography technique. By experiment it shows that flame front surface and inner flow field of methane explosion has distinctly fractal characteristic, the effect of the wrinkle of flame front surface and inner reactants on flame propagation can be directly reflect by fractal dimensions. Fractal dimension has a direct relation to flame structure and flame propagation characteristics, and it is the important parameter to scale the flame propagation velocity and flame temperature.     

Computational fluid dynamics simulations of hydrogen releases and vented deflagrations in large enclosures

This paper presents model predictions obtained with the CFD tool FLACS for hydrogen releases and vented deflagrations in containers and larger enclosures. The paper consists of two parts. The first part compares experimental results and model predictions for two test cases: experiments performed by Gexcon in 20-foot ISO containers (volume 33 m³) as part of the HySEA project and experiments conducted by SRI International and Sandia National Laboratories in a scaled warehouse geometry (volume 45.4 m³). The second part explores the use of the model system validated in the first part to accidental releases of hydrogen from forklift trucks inside a full-scale warehouse geometry (32 400 m³). The results demonstrate the importance of using realistic and reasonably accurate geometry models of the systems under consideration when performing CFD-based risk assessment studies. The discussion highlights the significant inherent uncertainty associated with quantitative risk assessments for vented hydrogen deflagrations in complex geometries. The suggestions for further work include a pragmatic approach for developing empirical correlations for pressure loads from vented hydrogen deflagrations in industrial warehouses with hydrogen-powered forklift trucks.     

Numerical analysis of hydrogen deflagration mitigation by venting through a duct

This paper presents a model and simulation results for the mitigation of a hydrogen–air deflagration by venting through a duct. A large eddy simulation (LES) model, applied previously to study both closed-vessel, and open atmosphere hydrogen–air deflagrations, was developed further to model a hydrogen–air explosion vented through a duct. Sub-grid scale (SGS) flame wrinkling factors were introduced to model major phenomena which contribute to the increase of flame surface area in vented deflagrations. Simulations were conducted to validate the model against 20% hydrogen–air mixture deflagrations (vent diameters 25 and 45 cm) and 10% hydrogen–air mixture deflagration (vent diameter 25 cm). There was reasonable correlation between the simulations and the experimental data. The comparative importance of different physical phenomena contributing to the flame wrinkling is discussed.     

Consequence prediction for dust explosions involving interconnected vessels using computational fluid dynamics modeling

Combustible dust explosions continue to present a significant threat toward operating personnel and pneumatic conveyance equipment in a wide variety of processing industries. Following ignition of suspended fuel within a primary enclosure volume, propagation of flame and pressure fronts toward upstream or downstream interconnected enclosures can result in devastating secondary explosions if not impeded through an appropriate isolation mechanism. In such occurrences, an accelerated flame front may result in flame jet ignition within the secondary vessel, greatly increasing the overall explosion severity. Unlike an isolated deflagration event with quantifiable reduced pressures (vent sizing according to NFPA 68 guidance), oscillation of pressure between primary and secondary process vessels leads to uncertain overpressure effects. Dependent on details of the application such as relative enclosure volumes, relief area, fuel type, suspended concentration, duct size, and duct length, the maximum system pressure in both interconnected vessels can be unpredictable. This study proposes the use of FLame ACceleration Simulator (FLACS) computational fluid dynamics (CFD) modeling to provide reliable consequence predictions for specific case scenarios of dust deflagrations involving interconnected equipment. Required minimum supplement to the originally calculated relief area (A_v) was determined through iterative simulation, allowing for reduced explosion pressures (P_red) to be maintained below theoretical enclosure design strengths (P_es).     

Extinguishment of hydrogen laminar diffusion flames by water vapor in a cup burner apparatus

Transient computations with full hydrogen chemistry were performed to reveal the flame structure and extinguishment process of co-flow, hydrogen diffusion flame suppressed by water vapor. As the concentration of water vapor was increased, the flame detached away from the burner brim and formed an edge flame at the flame base. Water vapor showed larger chemical inhibition effect than nitrogen when extinguishing hydrogen flame, which was attributed to its enhanced third body effect in the reaction H + O₂ + M = HO₂ + M. The minimum extinguishing concentration (MEC) of water vapor and nitrogen was predicted by Senecal formula and perfectly stirred reactor (PSR) model respectively. The MECs predicted by PSR model agree with the MECs calculated by Fluent, which shows that 1) the flame extinction is controlled by the flame base, and 2) radiation absorption is negligible. The measured MECs are in a reasonable agreement with the values calculated by Fluent, which demonstrates the accuracy of the CFD model. A simple model was used to investigate the relative importance of extinguishing mechanisms of water vapor. The results show that in a co-flow configuration the thermal cooling and chemical inhibition effect are the main extinguishing mechanisms in suppressing hydrogen diffusion cup burner flame.     

Medium-scale experiments on vented hydrogen deflagration

A series of medium-scale experiments on vented hydrogen deflagration was carried out at the KIT test side in a chamber of 1 × 1 × 1 m³ size with different vent areas. The experimental program was divided in three series: (1) uniform hydrogen–air mixtures; (2) stratified hydrogen–air mixtures within the enclosure; (3) a layer deflagration of uniform mixture. Different uniform hydrogen–air mixtures from 7 to 18% hydrogen were tested with variable vent areas 0.01–1.0 m². One test was done for rich mixture with 50% H₂. To vary a gradient of concentration, all the experiments with a stratified hydrogen–air mixtures had about 4%H₂ at the bottom and 10 to 25% H₂ at the top of the enclosure. Measurement system consisted of a set of pressure sensors and thermocouples inside and outside the enclosure. Four cameras combined with a schlieren system (BOS) for visual observation of combustion process through transparent sidewalls were used. Four experiments were selected as benchmark experiments to compare them with four times larger scale FM Global tests (Bauwens et al., 2011) and to provide experimental data for further CFD modelling. The nature of external explosion leading to the multiple pressure peak structure was investigated in details. Current work addresses knowledge gaps regarding indoor hydrogen accumulations and vented deflagrations. The experiments carried out within this work attend to contribute the data for improved criteria for hydrogen–air mixture and enclosure parameters to avoid unacceptable explosion overpressure. Based on theoretical analysis and current experimental data a further vent sizing technology for hydrogen deflagrations in confined spaces should be developed, taking into account the peculiarities of hydrogen–air mixture deflagrations in presence of obstacles, concentration gradients of hydrogen–air mixtures, dimensions of a layer of flammable cloud, vent inertia, etc.     

Turbulent deflagrations of mildly flammable refrigerant-air mixtures

With current concerns around global climate change, new hydrofluorocarbons with low Global Warming Potential (GWP) are being evaluated as alternative refrigerants. These alternative refrigerants, however, may be mildly flammable (as defined by the A2L safety group classification) and pose safety concerns for the heating, ventilation, air conditioning, and refrigeration (HVAC/R) industry. Consequently, careful assessments of different flammability characteristics and risks for these refrigerants are essential for their safe use in actual applications. In this study, deflagration propagation measurements for different mildly flammable refrigerants, including difluoromethane (R-32) and 2,3,3,3-tetrafluoropropene (R-1234yf), were undertaken in different geometries including a 9.1-m long conduit test rig and a closed cubical 12.5 m³ volume. Different tests were conducted for full volume deflagrations as well as with and without obstructions. Turbulent deflagration speeds for well-mixed, refrigerant-air mixtures have been shown to be orders of magnitude larger than their corresponding laminar flame speed values that are used in classifying flammable refrigerants in safety standards. Testing has also quantified the resulting severity as measured by the event overpressure which was shown to worsen with increased congestion or confinement as a consequence of increased induced turbulence. This work illustrates the importance for severity evaluations for actual large-scale or congested geometries of concern in practical applications. Even for mildly flammable refrigerants characterized by laminar flame speeds <2 cm/s, which is lower than the 10 cm/s limit for A2L refrigerants, relatively fast deflagrations can be generated for very congested geometries where downstream turbulence is generated as the flame front passes over obstacles in these situations.     

Comparison of blast curves from vapor cloud explosions

Several sets of blast curves are frequently used in the prediction of blast effects from vapor cloud explosions. However, they have not been validated by experiments since systematic experimental data have only become available in recent years. The aim of this paper is to present a comparison between the calculated blast curves and available experimental data. Also presented is a comparison between several blast curves. The comparison showed that for detonations and subsonic flames, the blast curves produced by one-dimensional numerical calculations are generally in agreement with experimental data. However, there is great difference between the measured and calculated overpressures for supersonic deflagrations. The experimental overpressures fall well below the calculated values and decay much faster. The discrepancy is more pronounced for less reactive mixtures. It can be concluded from the comparison that the prediction using one-dimensional numerical calculations is conservative and may be overly conservative for supersonic deflagrations.     

Development of a mitigation system against hydrogen-air deflagrations in nuclear power plants

A novel mitigation system against hydrogen-air deflagrations in nuclear power plant buildings is proposed and developed through a series of field experiments using explosion vessels of different volume sizes. The mitigation system is installed on the outer surface of the vessels, and it comprises flame arrester and explosion air bag. The flame arrester is made by stacking 10–20 sheets of fine-mesh wire screens, and the air bag is connected for holding explosion gas. The successful mitigation mechanism is the sequence of pressure-rise reduction by the air bag expansion, flame quenching by the flame arrester, and the slow burning of the gas mixture sucked from the air bag back into the vessel due to the negative pressure caused by the rapid condensation of water vapor inside the vessel. Necessary conditions for the successful mitigation system are discussed, and the practical unit size of flame arrester sheet is recommended.